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US 9,905,856 B1 29 embodiment,thecathodeactivematerialmaybemixedwith greaterthan1m,orevengreaterthan10m.Thelengthcan aconductivefiler,suchascarbonblack(CB),acetylene beasshortas1um,buttypicalyfrom10umto10mand black(AB),graphiteparticles,expandedgraphiteparticles, moretypicalyfrommicrometerstoafewmeters.Actualy, activatedcarbon,meso-porouscarbon,meso-carbonmicro thereisnotheoreticallimitationonthelengthofthistypeof bead(MCMB),carbonnano-tube(CNT),carbonnano-fiber 5 rope-shapebatery. (CNF),grapheneshet(alsoreferedtoasnanographene Theinventedrope-shapedalkalimetalbateryissoflex platelet,NGP),carbonfiber,oracombinationthereof.These iblethatthebaterycanbeeasilybenttohavearadiusof carbon/graphite/graphenematerials,containingsulfuror curvaturegreaterthan10cm.Thebateryisbendableto polysulfide,maybemadeintofineparticlesasthecathode substantiallyconform totheshapeofavoidorinterior activematerialtobeincorporatedinporesofthefoam 10compartmentinavehicle.Thevoidorinteriorcompartment maybeatrunk,door,hatch,sparetirecompartment,area underseatorareaunderdashboard.Thebateryisremovable from avehicleandisbendabletoconform totheshapeofa diferentvoidorinteriorcompartment. nano -structure that contains massive surfaces to support eithertheanodeactivematerial(e.g.NaorLicoating)orthe 15incorporatedintoagarment,belt,luggagestrap,weaponry cathodeactivematerial(e.g.S).Theporousnano-structure strap,musicalinstrumentstrap,helmet,hat,boot,fot shouldhaveporeshavingaporesizepreferablyfrom2nm covering,glove,wristcovering,watchband,jewelryitem, to50nm,preferably2nm-10nm.Theseporesareproperly animalcolaroranimalharness. sizedtoaccommodatetheelectrolyteatthecathodesideand Oneormoreunitsofinstantrope-shapedbaterycanbe toretainthecathodeactivematerialintheporesduring20removably incorporated agarment,belt,lugagestrap, repeatedcharges/discharges.Thesametypeofnano-struc- weaponrystrap,musicalinstrumentstrap,helmet,hat,boot, turemaybeimplementedattheanodesidetosuportthe anodeactivematerial. structureintheinventedLi-SorNa-Scel. In a prefered embodiment,thenano-scaled filaments (e.g.CNTs,CNFs,and/orNGPs)areformedintoaporous At the anode side,when an alkalimetal is used as the sole anodeactivematerialinanalkalimetalcel,thereisconcern 25 interiorradiusofaholow bicycleframe. aboutthe formation ofdendrites,which could lead to Inwhatfolows,weprovideexamplesforalargenumber Aditionaly,theinventedropebateryconformstothe internalshortingandthermalrunaway.Herein,wehaveused ofdiferenttypesofanodeactivematerials,cathodeactive twoapproaches,separatelyorincombination,toaddressing materials(from sulfurtovarioussulfurcompounds),and thisdendriteformationisue:oneinvolvingtheuseofa conductiveporouslayers(e.g.graphitefoam,graphene high-concentration electrolyteandtheothertheuse ofa 30 foam,andmetalfoam)toilustratethebestmodeofprac nano-structurecomposedofconductivenano-filamentsto ticingtheinstantinvention.Thesesilustrativeexamplesand supportthealkalimetalattheanode.Thenano-filamentmay supportthealkalimetalattheanode.Thenano-filamentmay otherportionsofinstantspecificationanddrawings,sepa beselectedfrom,asexamples,acarbonnanofiber(CNF), ratelyorincombinations,aremorethanadequatetoenable graphitenanofiber(GNF),carbonnano-tube(CNT),metal apersonofordinaryskilinthearttopracticetheinstant nano wire (MNW ),conductivenano-fibers obtained by 35 invention.However,theseexamplesshouldnotbeconstrued electro-spinning,conductiveelectro-spuncompositenano- aslimitingthescopeofinstantinvention. fibers,nano-scaledgrapheneplatelet(NGP),oracombina tionthereof.Thenano-filamentsmay bebondedby abinder Example 1:IlustrativeExamplesofElectronicaly materialselectedfrom apolymer,coaltarpitch,petroleum ConductivePorousRodsorLayersasanActive pitch,meso-phasepitch,coke,oraderivativethereof. 40 Material/Electrolyte-AccommodatingCurent Surprisinglyandsignificantly,thenano-structureprovides anenvironmentthatisconducivetouniform depositionof alkalimetalionsduringthebateryre-charge,totheextent Varioustypesofmetalfoams,carbonfoams,andfine thatnogeometricalysharpstructuresordendriteswere metalwebs/scrensarecomercialyavailableforuseas found in the anode after a large number of cycles.Not 45 conductive porous rods or layers in an anode or cathode wishingtobeboundbyanytheory,buttheaplicants (servingasacurentcolector);e.g.Nifoam,Cufoam,Al envisionthatthe3-Dnetworkofhighlyconductivenano foam,Tifoam,Nimesh/web,stainlesstelfibermesh,etc. filamentsprovideasubstantialyuniformatractionofalkali Metal-coatedpolymerfoamsandcarbonfoamsarealsoused metalionsbackontothefilamentsurfacesduringre-charg ascurentcolectors.Formakingmacroscopiccable-shaped ing.Furthermore,duetothenanometersizesofthefila-50 flexibleandshape-conformablebateries,themostdesirable ments,thereisalargeamountofsurfaceareaperunit thicknessrangesfortheseconductiveporouslayersare volumeorperunitweightofthenano-filaments.This 50-1000um,preferably100-80um,morepreferably200 ultra-highspecificsurfaceareaofersthealkalimetalionsan 600um.Formakingmicroscopiccable-shapebateries(hav oportunitytouniformlydepositathincoatingonfilament ingadiameterfrom10nmto10um,forinstance), surfaces. The high surface area readily accepts a large 5 graphene foams, graphene aerogel foam,porous carbon amountofalkalimetalionsintheliquidelectrolyte,enabling fibers(e.g.madebyelectro-spinningpolymerfibers,car highre-chargeratesforanalkalimetalsecondarybatery. bonizingthepolymerfibers,andactivatingtheresulting Thepresentlyinventedrope-shapedbateryhasmany carbonfibers),andporousgraphitefiberscanbeusedto uniquefeaturesandsomeofthesefeaturesandadvantages accommodatethemixtureofanelectrodeactivematerial aresummarizedbelow: 60andelectrolyte. Bydefinition,aropeshapebaterymeansabaterythat containsatleastarod-shapeorfilament-shapeanodeanda Example2:NiFoam andCVD Graphene rod-shapeorfilament-shapecathodecombinedintoabraid Foam-BasedPorousLayersSuportedonNiFoam or twist yarn. The battery has a length and a diameter or Templates thickneswherein theaspectratio(length-to-diameteror65 length-to-thicknesratio)isatleast10andpreferablyatleast TheprocedureforproducingCVD graphenefoam was 20.Therope-shapedalkalimetalbaterycanhavealength adaptedfromthatdisclosedinopenliterature:Chen,Z.etal. 30 Oneormoreunitsofinstantrope-shapebaterycanbe fotcovering,glove,wristcovering,watchband,jewelry item,animalcolaroranimalharness. ColectorPDF Image | FLEXIBLE AND SHAPE-CONFORMAL ROPE-SHAPE ALKALI METAL-SULFUR BATTERIES
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